CORROSSION ASPECTS

IN
REFINERY AND CATHODIC
PROTECTION
Part 1 of CP

3
Why Corrosion Control is Important ?
 Preserve Assets
 Reduce Maintenance Costs
 Reduce Inspection Cost
 Company/Government Requirement
 Preserve The Environment
 Petroleum refining is an industry that is undergoing intense amounts of
scrutiny in the United States from regulatory agencies and environmental
groups. As a result, releases of pollutants caused by corrosion leaks are
becoming a high-consequence event in US may be sometimes in India.
 The Clean Air Act of 1990 has forced refineries to implement a number of
costly measures to reduce their impact on the environment, both in the types
of products they produce and the manner in which they operate.
 The total cost of corrosion control in refineries is estimated at $3.692 billion.
 maintenance-related expenses are estimated at $1.767 billion annually,
 vessel turnaround expenses account for $1.425 billion annually,
 and fouling costs are approximately $0.500 billion annually.
 The costs associated with corrosion control in refineries include both
processing and water handling.

4
Corrosion in refinery - underground
 Corrosive Atmosphere – H2S, CO2, chlorides, and
high levels of dissolved solids
 Proximity to marine atmosphere
 Chemical discharges
 Presence of galvanic couples / dissimilar metals
 Elevated temperature due to concrete, flare, heat
dissipation through pipelines and equipments.
 Difference in soil Ph
 Difference in soil compaction i.e. Oxygen
concentration.

5
Cost of corrosion control methods
 Total annual cost: 188$ billion
 Protective Coatings: 174$ billions
 Cathodic Protection: 1.22 billions

6
Different types of corrosion in
refinary
 Uniform corrosion
 Galvanic corrosion
 Pitting corrosion
 Stress corrosion cracking (ssc)
 Crevice corrosion
 Intergraular attack (“IGA”);
 Selective leaching;
 Flow-Accelerated Corrosion;
7
Which Corrosion can be handled
with cathodic Protection ?

 Any metallic structure subjected to

Galvanic Corrosion
 Any metal placed in soil or in contact with
soil, water, seawater.
 UG/submarine pipelines, buried vessels,
tank bottom, pipelines carrying sea water,
water tanks, foundation Re-bars, jetty,
cooling towers etc.
8
Galvanic corrosion
 Corrosion is the deterioration of a material that results from a
reaction with its environment.
 For a metal in contact with an aqueous solution, the reaction
is an Electrochemical, involving the transfer of electrical
charge (electrons) across the metal/solution interface.
 The energy that exists in metals and causes them to corrode
spontaneously results from the process of converting ore to
metal. (Gibbs free energy -∆G).
 Surface atoms, have fewer interatomic bonds than internal
atoms have a better chance of leaving the crystal structure.

9
 If a metal atom leaves the crystal structure, it leaves behind
some of its bonding electrons (ne–) according to the following
oxidation reaction.
 When a metal is placed in an aqueous solution, other
possibilities for the metal ion arise because of the presence of
the polar water molecule.

10
 Galvanic corrosion in simple terms
When two metals (having different potentials) are
connected electrically and are immersed in an
electrolyte, current will be generated and the metal
which is less noble will corrode. Current from the
corroding metal will flow into the electrolyte, over
to a non corroding metal and back through the
connection between the two metals.

11
Corrosion of Iron – Diagrammatic
representation
CONVENTIONAL CURRENT FLOW ( I )

+ ELECTRON MIGRATION (e )
-
-
-
H+ o IONIZED SOLUTION OH
0
H + H =H
2
Fe(OH) , Fe (OH)
2 2 3
+ 0
H +e=H
e- H+
OH- Fe+ e-
OH- H+
e- +
H +e=H
0 OH-
Fe+
e-
e- H+
OH-
e- Fe
+ 0

Cu e- H +e=H
H+
Fe+ e-
OH- -
e- +
H+
0 Fe+
e-
H +e=H OH-
e- e-
H+ H+ OH-
e- + 0
OH- Fe+ e-
H +e=H

12
Conditions for Gal. Corrosion Cell
Formation

 Anode
 Cathode
 Electrolyte
 Electrical path between anode and
cathode
The metal where current leaves will get corroded and is
known as anode

The metal which receives current is known as cathode.

13
14
 Practical Galvanic Series
(i)
METAL VOLTS
CORRODED END – ANODIC OR LEAST NOBLE
COMMERCIALLY PURE MAGNESIUM - 1.75
MAGNESIUM ALLOY (6% Al, 3% Zn, 0.15 % Mn) - 1.6
ZINC -1.1
ALUMINIUM ALLOY (5% ZINC) -1.05
COMMERCIALLY PURE ALUMINIUM -0.8
MILD STEEL (CLEAN & SHINY) -0.5 TO -0.8
MILD STEEL (RUSTED) -0.2 TO -0.5
HIGH SILICON CAST IRON -0.2
CARBON, GRAPHITE, COKE +0.3
PROTECTED END–CATHODIC OR MOST NOBLE
SILVER +0.8
(i)
TYPICAL POTENTIAL NORMALLY OBSERVED IN NEUTRAL SOILS AND
WATER, MEASURED WITH RESPECT TO COPPER SULPHATE REFERENCE
ELECTRODE

15
Corrosion Reactions
 Fe further reacts with water to form
Fe(OH)2,Fe2O3,Fe3O4 (Corrosion product
in form of rust) – Anodic Reactions
 Cathodic reactions are:
2H+ + 2e-  H2
Hydrogen electrons hydrogen gas

Fe++  Fe +++ + e-

16
Corrosion Cell Formation
Oxidation reactions at anode
Fe ----------> Fe++ + 2 e-
Reduction reactions at cathode
In Highly acidic medium:
H + + e- ----------> H
H + H ---------> H2
In Neutral solution:
O2 + 4 H - ----------> 2 H20
O2 + 2 H2O + 4 e- -----> 4 (OH)-
( for highly aerated media)

17
18
How Corrosion Occurs ?

Galvanic corrosion

The differences in potential can be due to

 Coupling of dissimilar materials ( CS and SS)

 Non homogeneity in same material (Holidays in

coatings/inclusion in a metal)

 Non homogeneity in electrolyte (different salt

concentrations in soil, chemical composition, oxygen
concentration, moisture concentration etc.)

19
Factors affecting Corrosion
 Dissimilar soil
 Pipeline inside Casing pipe , paving
 Different size of anode & cathode area
 Old and new pipe
 Different aeration(O2 Conc.)
 Presence of Bacteria

20
Dissimilar Soils

21
Array of Corrosion Cell Due to
Different Soil

22
Different Size of Anode & Cathode

23
Old and New Pipe

24
Corrosion Due to Presence of
Bacteria in Soil

25
Different Aeration

26
Polarization Diagram

27
28
Corrosion Mitigation

 COATINGS – 90-95%
 CTE – majority
 PE coatings
 CATHODIC PROTECTION-10-15%
 ELECTROPLATING
 INHIBITORS
 SELECTION OF MATERIAL

29
 Coating & Cathodic Protection

Total Cost

Cost

Coating

Cathodic
Protection

0% 100 %
Part 2 of CP

31
 CORROSION

Any Metal that has been extracted from a naturally combined

state, has a tendency to revert to that state under the action
of oxygen and water. This action is called as “ Corrosion”
The commonest example being “ the rusting of steel “
Corrosion is a normal occurrence common to all metals not in their
natural state. The process itself is electrochemical in nature, very
similar to a battery, where electrons flow between anodic and
cathodic sites on metals. For corrosion to occur four elements are
required:

1. Anode – site where corrosion occurs and current flows from.

2. Cathode–site where no corrosion occurs and current flows to
3. Electrolyte – a medium capable of conducting electric current (i.e.
soil, water or concrete).
4. Metallic Path – connection between the anode and cathode.
CORROSION

“CORROSION CURRENT”

CATHODIC AREA ANODIC AREA CATHODIC AREA

CORRODING SURFACE
CORROSION
Basic Concepts :
• Corrosion is a natural process.
• All ferrous metals corrode at essentially the
same rate.
• Corrosion of iron and steel underground or
underwater results in selective and concentrated
attack
• Once leaks start to occur on an iron or steel
pipe, it continues at an exponentially rising rate
leading to disaster.

Effects of Corrosion
• Reduced life of components
• Reduced efficiency of component
• Endanger to life
• Enhanced Maintenance Cost
• Contamination of process fluids
CORROSION PROTECTION
MECHANISM

1. Primary - Coatings
2. Secondary - Cathodic Protection
 COATINGS
Presently following coatings are in use for pipeline protection:

• Coal Tar Enamel (CTE)

• Three Layer Polyethylene (3LPE)

• Fusion Bonded Epoxy (FBE)

• Polyurethanes (PU) (for Bullets)

• Tapes
All Plant UG pipelines in JERP is coated with CTE.
East-West pipeline coated with Three Layer polyethylene (3LPE).
Coating

 Coating is the primary protection for the buried structure

 Coating greatly reduces the current requirement, for a

new well coated pipe it is only 1% of bare pipeline

 It is extremely difficult to apply CP to a bare pipeline

because of the high current demand.

Generally mandated by regulations and recommended in

industry guidelines, e.g., ANSI B31.3
Corrosion Current Density for different Coatings

Minimum Protection Current Density (µ A/m2)

Soil/Water
Resistivity (Ohm- Coal Tar Enamel Three Layer Fusion Bonded
meter) (CTE) Poly- Epoxy (FBE)
ethylene
(3LPE)
10 to 100 300 50 125

< 10 2000 125 500

>100 200 35 90

Seawater 5000 NA NA
 THE RELATIONSHIP OF COATINGS
AND CATHODIC PROTECTION

External corrosion control for buried pipelines and other

metallic underground structures is accomplished
industry-wide by using dielectric coatings
supplemented by cathodic protection.

Relationships between these two corrosion control methods

are outlined to show how effective corrosion control
can be achieved. The long-term changes of protective
coatings in relation to their porosity, permeability, and
osmotic action under electrical potentials are
discussed.

Evaluation of existing criteria for adequate cathodic

protection of underground metals with poor or dis-
bonded coatings, in conditions conducive to stress
corrosion cracking and other localized corrosion
phenomena, indicates a need to consider revisions in
corrosion control measurement techniques and criteria
 CATHODIC PROTECTION – Definitions:

 Cathodic Protection is a Proven Technique to Control the Corrosion of a

Metal Surface by making the metal surface the Cathode (-ve) of an
Electrochemical Cell.

 This is achieved by maintaining the flow of an electrical current from the

Anode (+ve) through the electrolyte (soil/sand/water) into the surface of
the structure being protected.

 Use of DC Current from an external source to oppose the discharge of

corrosion current from anodic areas of the structure

 A means of rendering the metal immune from corrosion attack by causing

the direct current to flow from its electrolytic environment into the entire
metal surface- BS 7631- Part 1.

 Limitations: Cathodic Protection shall be considered as a technique to

control, rather than to provide immunity. DNV-RP-B401.
CRITERIA OF CP SYSTEM FOR STEEL
STRUCTURES

 Corrosion control can be achieved at various levels of Cathodic

Polarization depending upon the environmental condition. However in
the absence of data which demonstrates adequate Cathodic
Protection, one or more of the following shall apply :-

 A negative (Cathodic) potential of at least 850 mV measured with the

Cathodic protection applied. The potential is measured with respect to
a Cu/Cu-SO4 reference electrode contacting the electrolyte.

 A negative voltage shift of at least 300 mV measured between the

structure surface & saturated Cu/Cu-SO4 reference electrode
contacting the electrolyte – now removed.

 A minimum negative polarized voltage shift of 100 mV measured

between the structure surface and Cu/Cu-SO4 half cell. This
polarization voltage shift is to be determined by interrupting the
protective current and measuring the polarization decay
CRITERIA OF CP SYSTEM FOR STEEL STRUCTURES

Anodic Slope with 10%

moisture content and tap
water is 30 and 50 mV
per decade.

100mV of Cathodic
Polarisation would result
reduction in corrosion by
a factor of 2150 and 46
respectively.

100mV cathodic polarization on aerated curve from 650mV to 750mV reduces

corrosion rate by 1000 times.
For de-aerated condition, the rate of corrosion reduces by 30 times.
Metal Loss
 1 Amp Year Corrosion of Iron = 9.13 KG

 1 Amp / M2 Year Corrosion of Iron = 1.158 mm/Year

Or 0.05 mpy.
Factors effecting Polarization
 STANDARDS

 NACE SP0169-2007 Control of External Corrosion on under-

ground or submerged metallic piping system

 NACE RP0286-2002 Electrical Isolation of Cathodically protected

pipelines

 NACE SP0177-2007 Mitigation of alternating current and

Lightning effects on metallic structures and
corrosion control systems

 NACE TM0497-2002 Measurement techniques related to criteria

for cathodic protection of underground
submerged metallic piping system

 NACE RE- 052 Design, Installation, operation and

maintenance of impressed current deep anode
ground beds
CATHODIC PROTECTION TECHNIQUES
TYPES OF CP SYSTEMS

1. Sacrificial CP System

2. Impressed Current CP System

Part 3 of CP

48
Sacrificial
Anode CP
SACRIFICIAL CP SYSTEM

GALVANIC ANODE
A metal which, because of its relative position in the
Galvanic series, provides protection to
metal/metals that are more noble in the series,
When coupled with anSTATION
TEST electrolyte

PIPELINE

Protective Current
GALVANIC ANODE
 ELECTROCHEMICAL SERIES

Electrode Potential of Standard

Electrode at 25o C (V)
Al -1.66
Mg -2.37
Zn -1.76
Fe -0.44
H 0
Cu 0.34 to 0.52
Ag 0.80
Pt 1.2

From Handbook of chemistry and Physics. 41st Edition, 1959-1960, chemical Rubber Publishing Co.,
Half cell potential in solution of own salts, measured with respect to hydrogen reference electrode
TYPE OF A GALVANIC ANODE
Three main types of Galvanic anodes widely used for
protection
Magnesium Anode
Zinc Anode
Aluminum Anode Prepacked Galvanic anodes
GALVANIC ANODE SELECTION
ZINC
Zinc was the first galvanic metal to be used for
protecting steel. Zinc anodes continue to be
widely used for protection of steel in relatively
low resistivity electrolytes.
High Efficiency
Negligible rate of self corrosion/intergranual
corrosion
Low current output
Rate of consumption, Kg/A.year – 11.8
Potential, volts to copper/copper sulphate half cell
-1.1V
GALVANIC ANODE SELECTION
MAGNESIUM
Like Zinc, magnesium is also widely used for
protecting steel. Its relatively low rate of
consumption and higher potential make it
particulary suitable for high resistivity soils and
even certain water environments
High rate of intergranular corrosion especially in low
resistivity soils
High current output
Rate of consumption, Kg/A.year – 7.9
Potential, volts to copper/copper sulphate half cell
Low potential alloy -1.50 to 1.55V
High potentail alloy -1.7V
 GALVANIC ANODE SELECTION
ALUMINIUM
Aluminum lies in between magnesium and zinc in the
electochemical series. With its good electochemical
properties, such as low rate of consumption and a
potential that is slightly more electronegative than
that of zinc, aluminum is the obvious choice for
protection of steel in Offshore application
Capable of operating at high temperatures up to 1000C
Rate of consumption, Kg/A.year – 3.1 to 3.4
Potential, volts to copper/copper sulphate half cell: -1.1
to –1.15V
 GALVANIC ANODE BACKFILL

Before installing Zinc or Magnesium anodes in soil, it

is a standard practice to surround it with chemical
backfill. This chemical backfill is typically a mixture
of Gypsum, Bentonite clay and Sodium sulphate in
the proportion of 75%, 20% and 5% respectively.
The main reason that the galvanic anode is surrounded
by backfill to its installation in soil is to reduce its
resistance to earth.
Bare anode installed directly in soil would suffer from
local corrosion caused by variations in the
composition of soil leading to its non uniform
consumption.
And also chemical backfill keeps the immediate
environment around the anode moist.
ADVANTAGES & LIMITATIONS OF GALVANIC
ANODES
ADVANTAGES
 Easy to Design, Install and maintain
 High Reliability
 Low maintenance cost and maintenance
 Minimum interference problem with neighboring
structures
 Relatively easy monitoring
 Economical for Smaller structures
 Self regulated current output – hence low risk of
overprotection and hydrogen embrittlement
LIMITATIONS
 Low driving voltage
 Anodes need to be distributed all over due to limited
coverage design limitation
 Anodes need to be fitted close to the structure or on the
structure itself which may increase the burden on the
 APPLICATION OF A GALVANIC CP
SYSTEM

 Protection of short lengths of well coated pipeline in

moderate soil resistivity

 Protection of small areas of structure over relatively

short design lives, such as for temporary CP of
pipelines

 Hot spot protection on bare or poorly coated pipelines

where a comprehensive CP system may be
economically unviable

 Offshore structures – oil rigs, riser pipes.

 Vessels.
 Jetty steel piles.
 Offshore pipelines.
 Dams – Sluice Gates.
Part 4 of CP

59
 IMPRESSED CURRENT CP SYSTEM
An Impressed CP system uses an external DC power
source to provide current that will render the structure
to be protected
Voltage from some out side power source may be
impressed on the circuit between protected structure
and ground bed+VE DC POWER -VE
SOURCE

PIPELINE
 KEY ELEMENT AND MAIN FEATURES
OF AN IMPRESSED CURRENT CP
SYSTEM
KEY ELEMENT
Structure to be protected, Cathode
Impressed current Anodes
External DC Power source
Cabling to connect the above three elements

FEATURES
Requirement of external power
Variable current output
Longer design life of system
Needs regular monitoring and maintenance
Interference problems with neighboring structures need
consideration
CATHODIC PROTECTION SYSTEM CONNECTION SCHEME

DC
+ ve SOURCE - ve

CJB
E
W
P
L
AJB

Ref Cell

Anode bed
ESSENTIAL COMPONENTS OF ICCP
SYSTEM
 AC / D.C. Power Source

 Anode/ Anode Groundbed

 Reference Cells

 Test Stations

 Anode Junction Box

 Backfill Material
 DC POWER SOURCE
The AC / DC power source in an
impressed current CP system is a vital
element that supplies the current
needed for protecting the steel
structure.

A TRU is the commonly used DC source in impressed

current CP system. This equipment uses AC supply as input
which is transformed and rectified to provide a DC output.
TRUs can be manually controlled and/or automatically
controlled. Both single phase and three phase TRUs are
available.
Additionally there are Dc operated (CPPSM) units working
on DC power supply and AC/DC operated units working on
both AC and DC supplies .
 ICCP ANODES

Impressed current anodes discharge the current

provided by an external power source.
There is a wide choice of ICCP anodes available. Some of
these anodes are
 Scrap Iron anodes

 High silicon cast iron anodes

 Mixed metal oxide coated titanium anodes

 Platinized titanium /niobium anodes

 Magnetite anodes

 Long line Polymeric anodes (Anodeflex)

 ICCP ANODES
SCRAP IRON ANODES
These anodes are typically seen in the form of pipes, rails etc.
Scrap iron anodes were used in earlier times and continue to
be used for current drainage survey that are carried out to
estimate current demand prior to implementing CP.
Consumption rate about 10Kg/Amp. Year

HIGH SILICON CAST IRON ANODES

These are mostly widely used anodes in ICCP system with long
design life. These iron anodes available in a cylindrical rod
shape.
Consumption rate of these anodes, at about 0.2 to
0.4Kg/Amp.Year

MIXED METAL OXIDE( MMO) COATED TITANIUM ANODES

These anodes are composed of a highly conductive mixed metal
oxide film thermally applied to a titanium substrate.
Consumption rate of these anodes about 1mg/A.Year.
Additionally they are chemically stable and resistant to acidic
 ICCP ANODES

PLATINIZED TITANIUM/NIOBIUM ANODES

These anodes form an oxide film when treated as impressed
current anodes in fresh and salt water. The consumption
rate of these anodes is very low, of the order of
10mg/A.Year

MAGNETITE ANODES
These are steel based anode with low rate of consumption,
about 0.02Kg/A.Year. These anodes are not commercially
available in India

LONG LINE POLYMERIC ANODE (ANODEFLEX)

Anodeflex Can be placed in continuous close proximity to the
target structure. Uniform distribution of cathodic Protection
current evenly along its entire length. Supplied complete
with its own encapsulated coke breeze. Fast, Easy & cost
effective installation. Current output of 52 mA/m
 ICCP ANODE GROUND BED
A ground bed is a group of buried anodes that discharge the
current needed for CP of a structure. There are two types of
ground bed
 Remote ground bed
 Close ground bed
REMOTE GROUND BED
A remote anode ground bed is located far enough from the
pipeline such that the regions of influence surrounding the
pipeline and the ground bed remain more or less distinct.
Remote ground beds are typically used for protecting large
length of pipelines.

CLOSE GROUND BED

Close ground beds are used to protect limited sections of the
pipeline by providing local CP to areas of the pipeline in their
immediate vicinity. Such ground beds are used in a
distributed fashion to protect underground piping in
congested areas, such as plants, where protection using
remote ground beds may be unviable due to the shielding
effects of other structures in the vicinity
 ICCP ANODE GROUND BED
TYPES OF REMOTE GROUND BED
Three types of remote ground beds in use are
 Shallow Horizontal Anode bed
 Shallow Vertical Anode bed
 Deep well Anode bed
Shallow Horizontal Anode bed
These type of beds are generally proposed where low resistivity
is observed at 1-2 mtr depth and also where soil resistivity
very high at all the depth
Shallow Vertical Anode bed
Vertical anode bed are generally proposed where low resistivity
will be available at lower depth (3-5 mtr)
Deep well Anode bed
Deep well anode beds are generally proposed where resistivity at
depth is low
SCHEMATIC DIAGRAM OF DIFFERENT
ANODE GROUND BED
SCHEMATIC DIAGRAM OF DIFFERENT
ANODE GROUND BED
SCHEMATIC DIAGRAM OF DIFFERENT
ANODE GROUND BED
CARBONACEOUS BACKFILL

Impressed current anodes are surrounded by

a carbonaceous backfill before they are
installed in a ground bed. Carbonaceous
backfill increases the effective size of the
anode so that its resistance to earth is
lowered. Care should be taken to compact
or tamp the backfill so it can withstand the
consumption caused by current discharge.

Following type of back fill commonly used.

Calcined petroleum coke breeze this contains
97% to 99% of fixed carbon
 REFERENCE ELECTRODE
A electrode with a potential that may be considered constant
under similar conditions of measurement.

Half Cell – metal dipped into an electrolyte. In order to

measure its potential, it must be connected to another half
cell whose potential is already known.
 Absolute reference electrode is Hydrogen electrode –
potential in emf series is 0.
 Hydrogen electrode consists of Platinised Platinum
electrode dipped in a solution of unit hydrogen activity
and hydrogen gas bubbled at one atmosphere pressure.
 Other important half cell is Calomel Electrode
 Metal electrode of mercury surrounded by a solution of
potassium chloride saturated with mercurous chloride.
Potential of this electrode depends on conc. Of KCL.
PERMANENT REFERENCE CELL
COPPER- COPPER SULPHATE
REFERENCE CELL
 The Cu/CuSO4 ref. electrode or half cell is
most commonly used for Onshore C.P.
applications.
 Consists an electrode of electrolytic copper
in a saturated solution of copper sulphate.
SILVER/SILVER CHLORIDE REFERENCE
CELL
Ag wire coated with silver chloride so that
both Ag and AgCl.
The potential of the half cell will depend on
the chloride concentration.
 Sea Water or Marsy Areas.
ZINC Electrodes are also used in seawater as
well as in Soils and fresh water
COMPARISON OF GALVANIC ANODE
SYSTEM V/S IMPRESSED CURRENT
SYSTEM

Galvanic Anode Impressed Current

No external power reqd. Requires external power
Fixed driving voltage Voltage can be varied
Limited current Current can be varied
Suitable for low Can be designed for
resistivity electrolytes almost all current/life
requirements
Frequent monitoring and Regular monitoring and
maintenance not required maintenance required

Create minimum Interference problems

interference problems must be considered
CONCLUSION

CATHODIC PROTECTION OF COATED STRUCTURES

IS A PROVEN TECHNIQUE TO PROTECT
UNDERGROUND UTILITIES FROM RAVAGES OF
CORROSION.

IT CAN PREVENT CORROSION OF UNDERGROUND

METAL STRUCTURES FROM WHATEVER POINT OF
TIME APPLIED. HOWEVER, THE DAMAGE ALREADY
DONE CANNOT BE CURED BY THIS TECHNIQUE.
Part 5 of CP

78
 OTHER DEVICES USED IN CP SYSTEM
INSULATING JOINTS
To Limit the Leakage of Cathodic protection Current.
To Electrically split the Underground & above ground
structures
 OTHER DEVICES USED IN CP SYSTEM
SURGE DIVERTOR
A surge diverter is an
arcing device
provided across an
insulating Joint to
avoid open arcing it.
Surge diverters are
often used across
above ground
insulating Joints.
To protect buried
insulated joints 2
plate zinc grounding
cells are used.
 OTHER DEVICES USED IN CP SYSTEM
POLARISATION CELL
 AC grounding & DC
isolation of electric
equipment integral to a
cathodically protected
system
 Over voltage protection of
structures from AC faults
& lightning
 Mitigation of AC Voltage
Two types of Polarisation cell
are :
 Electrolytic type (Kirk cell)
 Soild state polariastion
cell
 OTHER DEVICES USED IN CP SYSTEM
CORROSION COUPON
Corrosion coupon are small pieces of same metal as the pipeline
used as substitute areas of exposed metal that simulate
coating defects on a pipeline. These coupons are used to
check the effect of corrosion and cathodic protection on a
pipeline without having to directly access it for measurement.
ER PROBES
ER or Electrical resistance probes are made of the same material
as the pipe and work on the principle that corrosion of metal
changes its shape and hence its resistance. ER probes are
typically used in areas where the rate of corrosion is expected
to high and/ or in areas where continual monitroing of
corrosion is considered necessary.
PIPE TO CABLE CONNECTION
Cable to pipe connection should be mechanically strong and
electrically conductive.
- Thermit Welding Process
- Soldering
- Pin brazing
 OTHER DEVICES USED IN CP SYSTEM
 Anode Jnction Box
 Cathode Junction
Box
 Connecting Cables
Part 6 of CP

84
Effect of soil property on polarization
Soil Resistivity
Corrosion Cell Properties
CP POLARISATION
Cathodic Reactions
Part 7 of CP

91
Cathodic Protection

History & Latest Trends

History
 1791: Luigi Galvani published his discovery
of bioelectricity
 1800: Alessandro Volta's battery, or voltaic
pile, made from alternating layers of zinc and
copper,
 1824: Sir Humphrey Davey
 Protection of copper in wooden ships with
Zn or Iron.
 The project started in 1761.
 1812: developed hypothesis that different
materials shows different electric state.
 First application: British worship
Sammarang made in India.
 … History
 1834: Faraday’s Law of
Electrolysis.
 1st Law: The mass of a substance altered
at an electrode during electrolysis is directly
proportional to the quantity of electricity
transferred at that electrode.
 2nd Law : the mass of an elemental material
altered at an electrode is directly
proportional to the element's equivalent
weight.
•1890 : First application of ICCP for protection of Ships by Thomas Alva
Edison.
•1902 : First application of ICCP for protection of Gas and Water pipelines
near Tramline.
•1905 : First Application for steam boilers and their tubes for Locomotives..
•1913 : Officially accepted as Electrochemical Protection Internationally.
 … History
 1906: Developed scientific fundamentals of cathodic
protection, Haber’s electrical circuit for cathodic
protection developed.
 1908: First Cu CuSO4 developed and used by
McCollum.
 1918: Test Station introduced for first time by
Bauer/Vogel in Berlin.
 1920: SACP used for protection of metal sheathing in
Germany
 1924 : Chicago Railroad Company provided SACP for
boiler tubes.
 1924: Alluminium anodes with DC applied for
protection of internals of hot water supply plant in
… History
 1928: First Cathodic Protection system was
implemented for long distance pipelines – R J
Kuhn – Father of CP in USA.
 1928: -0.85 Volt against sat. Cu CuSO4 reported
as protection level for steel – Kuhn
 Avg. 10 to 20 mA / M2 current density is
sufficient to arrest corrosion – Kuhn.
 First Basic standard for CP : DIN30676.
 Off – potential measurement method for CP
enforced in Europe since 1960.
 1980: Telluric Current Effects
 2001 : AC Corrosion
Shipping
JETTY
Concrete CP
 DETERIORATION MECHANISMS – External attack.
 ALKALI SILICA REACTIVITY (ASR)
 CORROSION OF REINFORCING STEEL
 DETERIORATION THROUGH CARBONATION
 DETERIORATION DUE TO CHLORIDE
 THE CORROSION MECHANIS
REPAIR TECHNIQUES OF RCC WITH CP
CP for RCC
Economic Comparison: Building and
walkway ( 30000 sq ft.)
Roney Palace Condominiums, Miami Beach,
Florida
Silver Jubilee Bridge (cathodic
protection), Runcorn, Cheshire

Project Description: Chloride contamination had caused the corrosion.

Repair Options: 1. remove all of the contaminated concrete: a hugely disruptive
and inefficient procedure.
Repair Option 2: use cathodic protection, where a low voltage current is passed
from an inert anode to the reinforcing steel.
Advance Features
ADVANCE FEATURES
 Other Major Structures
1. CATHODIC PREVENTION AND
CATHODIC PROTECTION OF NEW
AND EXISTING CONCRETE
ELEMENTS AT THE SYDNEY OPERA
HOUSE.

2. Statue of Liberty,

???????????

3. . ………….. Anything subjected to galvanic corrosion

Thank You

108